Building slab and wall construction



Feb. 5, 1935.

BUILDING SLAB AND WALL CONSTRUCTIONv 4riginal Filed Sept. 24, 1927 T. J.FosTE-R 1,989,798

2 Sheets-Sheet 1 T. J. FOSTER BUILDING SLB AND WALL CONSTRUCTION Feb. 5,1935.

original Filed sept. 24, 1927 2 Sheets-Sheet 2 (1R04/wut,

Patented Feb. 5, 1935 UNITED STATES PATENT oFFIcE OriginalapplicationSeptember 24, 1927, Serial `No. 221,780, now Patent No. 1,825,346, datedSeptember 29, 1931. Divided and this application January 29, 1931,Serial No. 512,116

11 Claims.

This application is a division of my cepending lapplication Serial No.221,780, filed September 24, 1927, (Patent No. 1,825,346, issuedSeptember 29, 1931) and the invention herein described and claimedrelates to materials for building construction, and is particularlyapplicable tothe construction of floors, ceilings, roofs, Walls andpartitions, Where non-combustibility and sound proofness combined withlight Weightv are desirable.

The invention aims to provide a light, strong, heat and sound prooffire-resisting slab which may be put in place With facility and does notrequire plastering to make an acceptable nish.

Further objects of the invention appear hereinafter in connection withthe description of the several embodiments illustrated in theaccompanying drawings, wherein Y Fig. 1 is a perspective view'of a Wallembodying the invention, showing the'various steps or stages inerection;

Fig. 2 is a cross-section through a ceiling slab at right angles to thedirection of the reinforcing strips, showing several varieties ofreinforcing and nailing strips suitable for supporting a floor having aWood iinish;

Fig. 3 is a similar view of a roof slab having a ycement or compositionnish; l I

Fig. 4 is a horizontal cross-section through an outside wallv embodyingthe invention showing a preferred form of stud construction;

Figs. 5 and 6 are similar views illustrating other forms of studconstruction; and

vFig. 7 is`a perspective View of a supporting sheet and stiffening barsready to be placed in a horizontal supporting frame and receive theaerated gysum or similar plastic material to form a slab.

This invention is illustrated in Fig. l as applied to an inside Wallsupported uponA floors carried by light Weight beams 11, the iioor slabs12 being composed of heat and sound insulating material from two tothree inches or more in thickness and provided with Wood screeds ornailing strips 13 for a Wood iioor 14, as is customary in apartments andoices and other buildings having this type of floor. Any type of floorconstruction may be used with partition walls embodying the invention,as it is adapted to both re proof and semi-fire proof or re resistingconstruction.

In the floor illustrated, the floor slab 12 is composed of suitable reresisting sheets or boards 15, such as sheet rock, gypsum boards, etc.,commonly used for partitions and ceilings, which (Cl. 'Y2-16) are laidacross the supporting beams 11 and insulate them from the floor slab asdescribed in my Patents Nos. 1,582,172 and 1,582,173, dated April 27,1926, and which in turn support the door filling 16 of light `Weightheat and sound insulating material, as described in my Patent No.1,717,444 dated June 18, 1929.

The floor supporting sheets 15 are preferably stiffened to give themsufficient strength and rigidity to support the filling 16 duringconstruction by ribs or bars 17, of Wood or metal, which are securedflat `against the floor Sheets for their entire length by means ofsuitable adhesive 18, such as asphaltum` or other sticky non-combustiblematerial, that retains its adhesive properties for an indenite period.These bars17-may be made the full depth of the iill and used to supportthe oor iinish 14 in Wooden floors, or they may be shalloWer and coveredby the fill, as desired. `Compositeribs 19 of wood and metal may beusedto advantage, as illustrated in Fig. 2.

Fastening the strengthening ribs to the sheets in the manner describedstops the vibration in the ribs so that soun'd will not be'conductedthrough them, thereby eliminating any direct means for conductingsoundsfrom the room above to the room below or vice versa.

Any suitable means `for protecting the beams may be attached to theunder side of the oor. For example, as shown in Fig. 1, the beamprotection is alforded by cast concrete channels 20, which may besecured to the under side of the floor slab 12 by means of metal strapsor hangers 21 embedded in the channels and having their upper endsprojecting through the sheets 15 and anchored by any suitable means.

The wall slabs or filling-in panels 22 (see Figs. 1 and 4) are held attop and bottom by soffit boards 23, which may be secured beneath thebeam covering by means of hangers or screws 24, and sills or plates 25,which may be laid along the floor upon the nailing strips Where it isdesired to erect a partition. The sills 25 are advantageously secured inposition upon the nailing strips 13 or floor slab 12 by means of asphaltor other adhesive.

The wall slabs 22 preferably are precast or made up in advance andstored to harden and dry out thoroughly before being erected in theirplaces in the structure, particularly if made of a wet material likecellular gypsum. In the form illustrated they comprise outer layers 26of plaster board, sheet rock, or the like, between which is a lling 27of cellular gypsum, or other heat and sound insulating material. Theedges of the their edges to the opposite sides of stiffening strips ofrigid material, and a lling of light weight plastic heat and soundinsulating material enclosed by said strips and lling the space betweensaid sheets, the outer side edges of said strips projecting beyond theedges of said facing sheets and being shaped or adapted for engagementwith similar shaped or adapted side edges of adjoining slabs in thestructure to form putty receiving open joints.

7. A substantially rigid heat and sound proof light-weight filling-inpanel for attachment to a supporting frame in the construction of Walls,partitions or roofs, consisting of a preformed slab comprisingsheet-like insulating material having all its edges secured to andstiifened by strips of rigid material forming with said sheet likematerial a shallow box-like structure substantially closed except at theside opposite said sheet-likematerial, and a filling of light weightplastic heat and sound insulating material embraced by said sheet-likematerial and said strips and filling the box-like structure formedthereby substantially flush with the tops of said strips.

8. A substantially rigid heat and sound proof light-weight filling-inpanel for attachment to a supporting frame in the construction of walls,partitions or roofs, consisting of a preformed slab comprising facingsheets of insulating material secured at their edges to the oppositesides of stiifening strips of rigid material forming with said sheets ofinsulating material a shallow boxlike structure substantially closed onall sides, and a lling of light weight plastic heat and sound insulatingmaterial entirely filling the space Within said shallow box-likestructure.

9. A substantially rigid heat and sound proof light-weight filling-in"panel for attachment to a supporting frame in the construction of walls,partitions or roofs, consisting of a preformed slab comprising a sheetof facing material having its edges secured to and stiffened by stripsor" rigid material, and a filling of light weight plastic heat and soundinsulating material filling the space enclosed by said strips.

10. A substantially rigid heat and sound proof light-weight filling-inpanel for attachment to a supporting frame in the construction of Walls,partitions or roofs, consisting of a preformed slab comprising sheets offacing material secured at their edges to the opposite sides ofstiffening strips of rigid material forming with said sheets a shallowbox-like structure substantially closed on all sides, and a filling oflight Weight plastic heat and sound insulating material iilling thespace within said shallow box-like structure.

11. A substantially rigid heat and sound proof light-weight lling-inpanel for attachment to a supporting frame in the construction of walls,partitions or roofs, consisting of a preformed slab comprising a sheetof facing material having its edges secured to and stiiened by strips ofsubstantially rigid material, additional stiffem'ng strip means securedto said sheet within the space defined by said edge stiffening stripsand of less height than the latter, and a filling of lightweight plasticheat and sound insulating material filling the space within said edgestiffening strips and embedding said additional stiffening strip means.

THOMAS J. FOSTER.

